Mattress, mattress topper and mattress cover

ABSTRACT

A mattress comprises a first and second memory foam layer, with a gel or elastomeric web layer therebetween. One of the foam layers may be substantially thicker than the other, providing either a firmer or softer mattress, depending on which side is employed as the mattress top.

This application claims priority from U.S. provisional application60891215, filed Feb. 22, 2008.

BACKGROUND OF THE INVENTION

This invention relates to mattresses, mattress toppers and mattresscovers, and more particularly to an improved mattress, mattress topperand mattress cover.

So called “memory foam” mattresses have become popular, where themattress is made from visco elastic foam, commonly referred to as memoryfoam, a high density foam product.

While comfortable to sleep on, mattresses made of such foam have severalpoints about which user complaints are raised. First, the mattresseshave no firmness and can be difficult to get out of for some, especiallythose who are less agile. Second, some users also complain that themattresses are too hot, especially in warmer weather or climates,resulting from the insulating properties of the foam. Further, theweight of the high density foam can result in a very heavy mattress thatcan be difficult to move or position.

SUMMARY OF THE INVENTION

In accordance with the invention, an improved mattress employs an outermemory foam layer with an inner gel or elastomeric layer.

Accordingly, it is an object of the present invention to provide animproved mattress.

It is a further object of the present invention to provide an improvedmattress topper.

It is yet another object of the present invention to provide an improvedmattress cover.

The subject matter of the present invention is particularly pointed outand distinctly claimed in the concluding portion of this specification.However, both the organization and method of operation, together withfurther advantages and objects thereof, may best be understood byreference to the following description taken in connection withaccompanying drawings wherein like reference characters refer to likeelements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side sectional view of a mattress in accordance with theinvention; and

FIG. 2 is a top view illustrating the gel layer of the mattress;

DETAILED DESCRIPTION

The system according to a preferred embodiment of the present inventioncomprises a memory foam outer layer with a gel or elastomer inner layer.When configured as a mattress, a thicker and thinner foam layer may beemployed on opposite sides of the mattress, with a gel or elastomerlayer in between, to provide different cushion and insulation propertiesto the mattress, depending on which side is used as the top.

Referring now to FIG. 1, a side sectional view of a mattress inaccordance with the invention, the mattress 10 comprises a first layer12 of memory foam, and a second thinner layer 16 of memory foam, with acentral gel web layer 14 positioned therebetween. The outer surfaces ofone or both of the foam layers 12, 16 may be provided with a cover layer18, 20, suitably of a “breathable” polyurethane, or athermo-mechanically expanded polytetrafluoroethylene (PTFE), to providea breathable yet moisture proof layer.

While the illustration of FIG. 1 does not include side panels to themattress, it will be understood that the mattress sides may be providedwith panels of foam, fabric or the like to present an aestheticappearance to the mattress as well as for protecting the layers andtheir assembly from tampering and dust and dirt.

An advantage provided by the mattress configuration is that the mattressmay be positioned with either layer 12 or layer 16 as the top layer, togive a firmer or softer mattress. With thinner layer 16 as the top, themattress is firmer, and as a result of the thinner foam, more likely toprovide a cooler sensation to the user. The mattress can thus beposition with the thinner layer as the top during summer or in warmerclimates.

Alternatively, for a softer configuration, the mattress is positionedfor use with thicker layer 12 as the top layer (by flipping the mattressover). This position may also be desirable in colder climates or inwinter, providing a more insulative experience than with the thinnerlayer side up.

The configuration of the gel web layer 14 may be in the form of a web ofdiamond shaped cells or, as in FIG. 2, a top view illustrating the layer14 in the preferred embodiment, hexagonal cells. In FIG. 2, the top foamlayer 12 is peeled away to show the placement and configuration of layer14 relative to layers 12, 16. Further, other shapes such as rectangles,oblong shapes, circles, etc., may be employed for the shape of thecells. The cells comprise walls 22 and open areas 24 therebetween,providing support yet enabling a reduced overall weight to the mattress.The shape of the cells helps determine the firmness of the layer 14,which also contributes to the overall response of the mattress. Layer 14is suitably a gelatinous elastomer or gelatinous viscoelastomer.Suitable compositions for the gelatinous layer are such as described inU.S. Pat. Nos. 5,456,072, 5,362,834, 5,334,646, 5,191,752, 4,913,755,5,334,646, 4,369,284, 5,262,468, 4,618,213, 5,336,708. The gelsdescribed in these patents that can be suitable are typically 100 partsby weight of a high viscosity triblock copolymer and 200 to 1600(approximately) parts plasticizing oil by weight (e.g., mineral oils),with changes in the amount of oil changing the flexibility of the gel.

In addition to use as a stand alone mattress, the concept of the presentinvention may be applied to use as a mattress topper, wherein a somewhatthinner set of layers is employed for positioning on top of an existingmattress. For example, a stand alone mattress in accordance with theinvention is 5 or 6 inches in thickness, while a mattress topper is 3inches thickness.

Still further, the configuration may be employed as a mattress pad, withthe addition of a side skirt adapted to fit around at least the cornersof an existing mattress, so as to maintain the pad in position on top ofa mattress.

Suitably the memory foam employed is a 4 or 5 or 6 pound foam.

While a preferred embodiment of the present invention has been shown anddescribed, it will be apparent to those skilled in the art that manychanges and modifications may be made without departing from theinvention in its broader aspects. The appended claims are thereforeintended to cover all such changes and modifications as fall within thetrue spirit and scope of the invention.

1. A mattress comprising: a first layer memory foam having a firstthickness; a second layer memory foam having a second thickness; and anelastomeric layer therebetween.
 2. The mattress according to claim 1,wherein a face of at least one of said first and second layers of memoryfoam away from the faces thereof adjacent said elastomeric layer, has a“breathable” polyurethane, or a thermo-mechanically expandedpolytetrafluoroethylene (PTFE) layer thereon.
 3. The mattress accordingto claim 1, wherein said elastomeric layer comprises plural cells havingwalls and open areas therebetween.
 4. The mattress according to claim 3,wherein said cell walls define triangular shape open areas.
 5. Themattress according to claim 3, wherein said cell walls define circularshape open areas.
 6. The mattress according to claim 3, wherein saidcell walls define hexagonal shape open areas.
 7. The mattress accordingto claim 3, wherein said cell walls define rectangular shape open areas.8. The mattress according to claim 1, further comprising a fastener toenable securing of said mattress when placed on top of box spring or onanother mattress.
 9. The mattress according to claim 8, wherein saidfastener comprises a peripheral skirt member adapted for extending overat least corners of said box spring or said another mattress.
 10. Amattress pad, comprising: a first layer memory foam having a firstthickness; a second layer memory foam having a second thickness; and anelastomeric layer therebetween.
 11. The mattress pad according to claim10, wherein a face of at least one of said first and second layers ofmemory foam away from the faces thereof adjacent said elastomeric layer,has a “breathable” polyurethane, or a thermo-mechanically expandedpolytetrafluoroethylene (PTFE) layer thereon.
 12. The mattress padaccording to claim 1, wherein said elastomeric layer comprises pluralcells having walls and open areas therebetween.
 13. The mattress padaccording to claim 12, wherein said cell walls define triangular shapeopen areas.
 14. The mattress pad according to claim 12, wherein saidcell walls define circular shape open areas.
 15. The mattress padaccording to claim 12, wherein said cell walls define hexagonal shapeopen areas.
 16. The mattress according to claim 12, wherein said cellwalls define rectangular shape open areas.
 17. The mattress padaccording to claim 10, further comprising a fastener to enable securingof said mattress when placed on top of box spring or on anothermattress.
 18. The mattress pad according to claim 17, wherein saidfastener comprises a peripheral skirt member adapted for extending overat least corners of said box spring or said another mattress.